Harley Davidson FLHRC 2006. Maintenance & Repair Manual - page 36
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AC OUTPUT CHECK
1.
See Figure 1-17. To test AC output:
2.
Disconnect stator from voltage regulator.
a. Connect an AC voltmeter across any two stator con-
nector socket combinations.
b. Run the engine at 2000 rpm. The AC voltage output
should be greater than 30-40 volts AC.
c. Repeat AC voltage test across the other two stator
socket combinations.
3.
If the output is below specifications, charging problem
could be a faulty rotor or stator. Replace the rotor or sta-
tor.
f2432x8x
4.
Check the output again as described under CURRENT
OUTPUT TEST given earlier.
Figure 1-15. Test for Grounded Stator
f2433x8x
f2434x8x
Figure 1-16. Check for Stator Resistance
Figure 1-17. Check AC Output
Open Stator
1.
Turn ignition keyswitch OFF.
2.
Using ohmmeter probe, test for electrical continuity
between all three stator connector socket combinations,
that is, 1-2, 2-3, 1-3.
a. See Figure 1-16.
b. Resistance across all three stator socket combina-
tions should be less than 1 ohm (typically 0.1-0.3
ohms).
c. If resistance is greater than 1 ohm, then stator is
OPEN and must be replaced.
2006 Touring: Starting & Charging
1-19
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BATTERY TESTING
1.8
GENERAL
HD-48053
Three different procedures may be performed to provide a
good indicator of battery condition: a voltage test, a conduc-
tance test, or a load test.
A battery may be tested, whether fully charged or not, via the
voltmeter or conductance tests. In order to perform a load
test, however, the battery must be fully charged.
VOLTMETER TEST
Refer to Table 1-5. The voltmeter test provides a general indi-
cator of battery condition. Check the voltage of the battery to
Figure 1-18. Advanced Battery Conductance and
verify that it is in a 100% fully charged condition. If the open
Electrical System Analyzer (Part No. HD-48053)
circuit (disconnected) voltage reading is below 12.6V, charge
the battery and then recheck the voltage after the battery has
x0661x3x
set for one to two hours. If the voltage reading is 12.7V or
above, perform the LOAD TEST described in this section.
Table 1-5. Voltmeter Test
Voltage (OCV)
State of Charge
12.7
100%
12.6
75%
12.3
50%
12.0
25%
11.8
0%
CONDUCTANCE TEST
Figure 1-19. Battery Test Results-Printout
Test battery using the ADVANCED BATTERY CONDUC-
TANCE AND ELECTRICAL SYSTEM ANALYZER
(HD-
48053). Proceed as follows:
● CHARGE & RETEST-Fully charge the battery and
1.
Connect the analyzer leads to the battery.
retest.
2.
Follow the instructions in the analyzer instruction manual
to perform a battery test.
● REPLACE BATTERY-replace the battery and retest.
The test results will include a decision on the battery condi-
● BAD CELL-REPLACE-replace the battery and retest.
tion, the measured state of charge and the measured CCA.
See Figure 1-19. The analyzer printer will provide you with a
NOTE
printout including one of five possible test results:
A REPLACE BATTERY test result may also mean a poor con-
● GOOD BATTERY-return the battery to service.
nection between the battery cables and the motorcycle. After
disconnecting the battery cables from the battery, retest the
● GOOD-RECHARGE-fully charge the battery and return
battery using the out-of-vehicle test before replacing.
to service.
1-20
2006 Touring: Starting & Charging
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LOAD TEST
VOLTS
The load test measures battery performance under full cur-
AMPS
rent load and is the best indicator of battery condition. To load
Load
test the battery, proceed as follows:
Tester
1.
Remove seat.
1WARNING
Always disconnect the negative battery cable first. If the
positive cable should contact ground with the negative
cable installed, the resulting sparks may cause a battery
explosion which could result in death or serious injury.
Induction
Pickup
2.
Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
3.
Unthread bolt and remove battery positive cable (red)
from battery positive (+) terminal.
BATTERY
4.
Using a T-40 TORX drive head, loosen bolt to move lip of
d0428x8x
hold-down clamp off edge of battery. Remove battery
from battery box.
Figure 1-20. Load Test Battery
CAUTION
Load testing a discharged battery can result in perma-
8.
Load battery at 50% of CCA rating using the load tester.
nent battery damage.
Voltage reading after 15 seconds should be 9.6V or more
at 70°F. (21°C).
5.
Always fully charge the battery before testing or test
readings will be incorrect. Load testing a discharged bat-
Table 1-6. Battery Load Test
tery can also result in permanent battery damage.
COLD CRANKING
100%
50%
6.
After charging, allow battery to stand for at least one
AMPERAGE (CCA)
hour before testing.
TOURING
300
150
1WARNING
Always turn the battery load tester OFF before connect-
1WARNING
ing the tester cables to the battery terminals. Connecting
Always turn the battery load tester OFF before discon-
tester cables with the load tester ON could cause a spark
necting the tester cables from the battery terminals. Dis-
resulting in a battery explosion. A battery explosion may
connecting tester cables with the load tester ON could
rupture the battery case causing a discharge or spray of
cause a spark resulting in a battery explosion. A battery
sulfuric acid which could result in death or serious
explosion may rupture the battery case causing a dis-
injury.
charge or spray of sulfuric acid which could result in
death or serious injury.
7.
Connect tester leads to battery posts and place induction
pickup over negative (black) cable. See Figure 1-20.
9.
Place the fully charged battery into the battery box, ter-
minal side forward.
CAUTION
CAUTION
To avoid load tester and/or battery damage, do not leave
the load tester switch turned ON for more than 20 sec-
Connect the cables to the correct battery terminals or
onds.
damage to the motorcycle electrical system will occur.
2006 Touring: Starting & Charging
1-21
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11. Insert bolt through battery negative cable (black) into
1WARNING
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
Always connect the positive battery cable first. If the pos-
itive cable should contact ground with the negative cable
12. Apply a light coat of petroleum jelly or corrosion retardant
installed, the resulting sparks may cause a battery explo-
material to both battery terminals.
sion which could result in death or serious injury.
13. Rotate the hold-down clamp so that the lip (with rubber
pad) rests on the edge of the battery. Using a T-40 TORX
CAUTION
drive head, tighten the clamp bolt to 15-20 ft-lbs (20-27
Nm).
Overtightening bolts can damage battery terminals.
14. Install seat.
10. Insert bolt through battery positive cable
(red) into
threaded hole of battery positive (+) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
1-22
2006 Touring: Starting & Charging
INSTRUMENTS
2
Table Of Contents
SUBJECT
PAGE NO.
2.1 Checking For Diagnostic Trouble Codes
2-1
2.2 Initial Diagnostic Check: Speedometer
2-4
2.3 Speedometer Self Diagnostics
2-13
2.4 Speedometer/Tachometer
2-15
2.5 Breakout Box: Speedometer
2-19
2.6 Fuel Gauge
2-20
2.7 Oil, Air and Voltmeter Gauges
2-21
2.8 Indicator Lamps: FLTR, FLHT/C/U
2-23
2.9 Indicator Lamps: FLHR/C/S
2-25
2.10 DTC B1004, B1005
2-27
2.11 DTC B1006, B1007
2-31
2.12 DTC B1008
2-33
2.13 DTC U1016
2-36
2.14 DTC U1064, U1255
2-42
2.15 DTC U1300, U1301 or "BUS Er"
2-48
HOME
CHECKING FOR DIAGNOSTIC TROUBLE CODES
2.1
CHECK ENGINE LAMP
To diagnose ECM or ICM system problems, start by observ-
ing the behavior of the check engine lamp.
60
40
50
70
30
50
40
80
NOTES
30
90
20
MPH
RPM x100
● See Figure 2-2. “Key ON” means that the ignition key is
20
100
10
turned to ON and the engine stop switch is set to RUN
10
110
(although the engine is not running).
0
120
0
● When the ignition switch is turned ON, the check engine
lamp will illuminate for approximately four seconds and
TI
-D
-D
then turn off.
● If the check engine lamp is not illuminated at Key ON.
See Section
2.2 INITIAL DIAGNOSTIC CHECK:
SPEEDOMETER.
Check Engine Lamp
f2160x8x
● If the check engine lamp comes on late (after 20 sec-
Figure 2-1. Speedometer
onds). See Section 2.2 INITIAL DIAGNOSTIC CHECK:
SPEEDOMETER.
● If the check engine lamp fails to turn OFF after the initial
four second period. See Section 2.2 INITIAL DIAGNOS-
TIC CHECK: SPEEDOMETER.
1.
See Figure 2-3. After lamp turns off after being illumi-
nated for the first four second period, one of three situa-
tions may occur.
a. The lamp remains off. This indicates there are no
current fault conditions or stored DTC’s currently
detected by the ICM or ECM.
b. The lamp stays off for only four seconds and then
comes back on for an eight second period. This indi-
f2080x8x
cates a DTC is stored, but no current DTC exists.
c. If the lamp remains on beyond the eight second
Figure 2-2. Ignition Switch (FLHX, FLHT/C/U, FLTR)
period, then a current DTC exists.
2.
See CODE TYPES which follows for a complete descrip-
tion of DTC formats.
NOTES
Some DTC’s can only be fully diagnosed during actuation.
For example, a problem with the ignition coil will be consid-
ered a current fault even after the problem is corrected, since
the ECM/ICM will not know of its resolution until after the coil
is exercised by vehicle start sequence. In this manner, there
may sometimes be a false indication of a current DTC.
2006 Touring: Instruments
2-1
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● If the check engine lamp fails to turn OFF after the initial
SECURITY LAMP
four second period, see Section 2.2 INITIAL DIAGNOS-
TIC CHECK: SPEEDOMETER.
To diagnose TSM/TSSM system problems, start by observing
1.
See Figure 2-3. After lamp turns off after being illumi-
the behavior of the security lamp.
nated for the first four second period, one of three situa-
tions may occur.
NOTES
a. The lamp remains off. This indicates there are no
● To provide an indication of TSSM DTC’s, the security
current fault conditions or stored DTC’s currently
lamp is enabled on TSSM models.
detected by the ICM or ECM.
b. The lamp stays off for only four seconds and then
● See Figure 2-2. “Key ON” means that the ignition key is
comes back on for an eight second period. This indi-
turned to ON and the engine stop switch is set to RUN
cates a DTC is stored, but no current DTC exists.
(although the engine is not running).
c. If the lamp remains on beyond the eight second
● When the ignition switch is turned ON, the check engine
period, then a current DTC exists.
lamp will illuminate for approximately four seconds and
2.
See CODE TYPES which follows for a complete descrip-
then turn off.
tion of DTC formats.
● If the check engine lamp is not illuminated at Key ON,
NOTE
see Section 2.2 INITIAL DIAGNOSTIC CHECK: SPEED-
Some DTC’s can only be fully diagnosed during actuation.
OMETER.
For example, a problem with the turn signals will be consid-
ered a current fault even after the problem is corrected, since
● If the check engine lamp comes on late (after 20 sec-
the TSM/TSSM will not know of its resolution until after the
onds), see Section 2.2 INITIAL DIAGNOSTIC CHECK:
turn signals are activated. In this manner, there may some-
SPEEDOMETER.
times be a false indication of a DTC.
ON
4 Sec.
A
Lamp OFF: No Current or Historic DTC’s
OFF
Key ON
Lamp ON 8 Seconds:
Only Historic DTC’s Exist
ON
4 Sec.
8 Sec.
B
Lamp OFF
OFF
4 Sec.
Key ON
Lamp Remains ON: Current DTC *
ON
4 Sec.
C
OFF
4 Sec.
Key ON
* Historic DTC’s May Also Exist
Figure 2-3. Check Engine and Security Lamp Operation
2-2
2006 Touring: Instruments
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CODE TYPES
RETRIEVING DIAGNOSTIC
TROUBLE CODES
There are two types of DTC’s: current and historic. If a DTC is
stored, it can be read using speedometer self diagnostics.
See Section 2.3 SPEEDOMETER SELF DIAGNOSTICS.
The engine management system provides two levels of diag-
nostics.
All DTC’s reside in the memory of the ECM/ICM, TSM/TSSM,
speedometer or tachometer until the code is cleared by use
● The most sophisticated mode employs a computer
of the speedometer self diagnostics. See Section
2.3
based diagnostic package called DIGITAL TECHNICIAN
SPEEDOMETER SELF DIAGNOSTICS.
(Part No. HD-44750).
A historic DTC is also cleared after a total of 50 trips has
● The second mode requires using the speedometer self
elapsed. A trip consists of a start and run cycle. After the 50
diagnostics. Speedometer, tachometer
(if equipped),
trip retention period, the DTC is automatically erased from
TSM/TSSM and ECM/ICM DTC’s can be accessed and
memory providing that no subsequent faults of the same type
cleared. See Section 2.3 SPEEDOMETER SELF DIAG-
are detected in that period.
NOSTICS.
Current
Current DTC’s are those which presently disrupt motorcycle
operation. See the appropriate flow charts for solutions.
MULTIPLE DIAGNOSTIC TROUBLE
CODES
Historic
If a particular problem happens to resolve itself, the active
While it is possible for more than one fault to occur and set
status is dropped and it becomes a historic fault rather than a
more than one DTC, there are several conditions which may
current fault.
result in one fault setting multiple DTC’s:
Historic trouble codes can only be retrieved using a computer
Serial data DTC’s
(DTC U1016, U1064, U1097, U1255,
based diagnostic package called DIGITAL TECHNICIAN
U1300 and U1301) may be accompanied by other codes.
(Part No. HD-44750).
Always correct the serial data DTC’s before resolving the
other codes.
Historic trouble codes are stored for a length of time to assist
in the diagnosis of intermittent faults.
For proper resolution of multiple DTC’s refer to DTC priority
chart page 2-6,Table 2-2.
It is important to note that historic trouble codes may also be
present whenever the system indicates the existence of a
current fault. See MULTIPLE DIAGNOSTIC TROUBLE
CODES if multiple DTC’s are found.
Diagnostic charts are designed for use with current trouble
codes and as a result they frequently suggest wire repair or
part replacement.
2006 Touring: Instruments
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INITIAL DIAGNOSTIC CHECK: SPEEDOMETER
2.2
GENERAL
● Constant power is supplied to the speedometer through
terminal 5 of connector [39]. The speedometer turns on
when power is applied to terminal 1 of connector [39].
The speedometer goes through an initialization
sequence every time power is removed and re-applied to
terminal 6. The visible part of this sequence is the check
engine lamp (in “run” mode), security lamp (models with
security only), backlighting, odometer and fuel level (EFI
only). Upon key ON, the check engine lamp and security
lamp will illuminate for 4 seconds and then (if parameters
are normal) go out.
● To locate faulty circuits or other system problems, follow
Fuse
Block
Maxi-Fuse
the diagnostic flow charts and tests in this section. For a
Cover
systematic approach, always begin with INITIAL DIAG-
f2206x8x
NOSTICS which follows. Read the general information
and then work your way through the flow chart box by
Figure 2-4. Remove Left Side Cover
box.
● Loss of power on any of the four power inputs will
change speedometer behavior. Refer to Table
2-1.
Speedometer Function Chart-Loss Of Input.
Diagnostic Notes
If a numbered circle appears adjacent to a flow chart box,
then more information is offered in the diagnostic notes. Many
diagnostic notes contain supplemental information, descrip-
tions of various diagnostic tools or references to other parts
of the manual where information on the location and removal
of components may be obtained.
Maxi-Fuse
f2207x8x
Circuit Diagram/Wire Harness
Figure 2-5. Remove Maxi-Fuse Cover
Connector Table
When working through a flow chart, refer to the illustrations,
the associated circuit diagram and the wire harness connec-
tor table as necessary. The wire harness connector table for
each circuit diagram identifies the connector number, descrip-
tion, type and general location.
In order to perform most diagnostic routines, a Breakout Box
and a digital volt/ohm meter (DVOM) are required. See Sec-
tion 2.5 BREAKOUT BOX: SPEEDOMETER.
To perform the circuit checks with any degree of efficiency, a
familiarity with the various wire connectors is also necessary.
2-4
2006 Touring: Instruments
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INITIAL DIAGNOSTICS
Spare Fuse
Holder
Fuse Block
Diagnostic Tips
Cover
● If Speedometer reads “BUS Er” with the ignition key
turned ON (engine stop switch at RUN with the engine
off), check data bus for an open or short to ground.
between data link connector [91A] terminal 3 and ICM
connector [10B] terminal 12 (carbureted models), ECM
connector [78B] terminal 5 (EFI models), TSSM connec-
tor [30B] terminal 3, Speedometer connector [39B] termi-
nal
2 or tachometer
(if equipped) connector
[108B]
terminal 2.
● Check for an open data test terminal between data link
f2209x8x
connector [91A] terminal 3 and TSM/TSSM connector
[30B] terminal 3. With ignition key turned ON, serial data
f2203x8x
8
7
bus voltage should be typically 0.6-0.8 volts. The range
of acceptable voltage is greater than 0 and less than 7.0
9
volts.
6
10
● To identify intermittents, wiggle instrument and/or vehicle
5
harness while performing steps in the Diagnostic Check
11
charts.
4
Diagnostic Notes
The reference numbers below correlate with the circled num-
bers on the diagnostic check flow charts. See page 2-11.
2
3
1
1.
Connect BREAKOUT BOX (Part No. HD-42682) and
INSTRUMENT HARNESS ADAPTERS (Part No. HD-
1.
Headlamp
7.
Radio Power
46601) between wire harness and speedometer.
2.
Ignition
8.
Accessory
3.
Lighting
9.
Battery
All Speedometer DTC’s are listed on page 2-6 in Table 2-2.
4.
Instruments
10.
Brake Light Relay
5.
Brakes/Cruise
11.
P&A
6.
Radio Memory
Other Codes
Figure 2-6. Fuse Block (FLHX, FLHTC/U, FLTR)
See Section 3.9 INITIAL DIAGNOSTIC CHECK: TSM/TSSM
for any DTC’s related to the turn signal module (TSM) or turn
signal security module (TSSM).
See Section 4.4 INITIAL DIAGNOSTIC CHECK: ICM for any
DTC’s related to the ICM.
See Section 5.5 INITIAL DIAGNOSTIC CHECK: EFI for any
DTC’s related to the ECM.
2006 Touring: Instruments
2-5
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Table 2-1. Speedometer Function Chart-Loss Of Input
Terminal 5
Terminal 8 and 11
Terminal 1 (IGN)
Terminal 6 (ACC)
Terminal 7 (GRD)
(Constant)
(Reset Switch)
● Security lamp
● Will not “wow”
● Speedometer will
● Speedometer com-
● No reset switch
glows dimly dur-
be non-functional
pletely non-functional
function
● Turn signals still functional
ing 4-second
in accessory and
● Diagnostics absent
● Will not “wow”
● Speedometer will indicate
bulb check
ignition modes
vehicle speed (zero)
● Security lamp still
● Tachometer unaffected
performs 4-sec-
● Security lamp still func-
ond bulb check in
tional
ignition mode
● Check engine lamp and
battery lamp non-func-
tional
● Diagnostics absent
Table 2-2. Speedometer/Tachometer Diagnostic Trouble Codes (DTC) Priority Chart
DTC
PRIORITY
FAULT CONDITION
SOLUTION
MODULE
2.15 DTC U1300, U1301
“BUS Er”
1
Serial data bus shorted low/open/high
Speedometer/tachometer
or “BUS ER”
2.15 DTC U1300, U1301
U1300
2
Serial data bus shorted low
Speedometer/tachometer
or “BUS ER”
2.15 DTC U1300, U1301
U1301
3
Serial data bus shorted open/high
Speedometer/tachometer
or “BUS ER”
U1016
4
Loss of ECM serial data
2.13 DTC U1016
Speedometer/tachometer
U1064
5
Loss of TSM/TSSM serial data
2.14 DTC U1064, U1255
Speedometer/tachometer
Missing response from other module
U1255
6
2.14 DTC U1064, U1255
Speedometer/tachometer
(TSM/TSSM and/or ICM/ECM) at startup
B1007
7
Ignition line overvoltage
2.11 DTC B1006, B1007
Speedometer/tachometer
B1006
8
Accessory line overvoltage
2.11 DTC B1006, B1007
Speedometer/tachometer
B1008
9
Reset switch closed
2.12 DTC B1008
Speedometer
B1004
10
Fuel level sending unit low
2.10 DTC B1004, B1005
Speedometer
B1005
11
Fuel level sending unit high/open
2.10 DTC B1004, B1005
Speedometer
2-6
2006 Touring: Instruments
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f2353k8b
[156B] [156A]
Main to Interconnect
Radio
[27A]
6
6
Harness
[27B]
5
5
9
4
4
3
3
GY
BK
2
2
BK
LtGN/V
1
1
LtGN/V
O
1
2
3
4 5 6 7 8 9 10 11 12
[30B]
BN/GY
1
2
3
4 5 6 7 8 9 10 11 12
[30A]
TSM/TSSM
BN/GY
[39B]
GY
BK
1
2
3
4 5 6 7 8 9 10 11 12
[39A]
1
2
3
4 5 6 7 8 9 10 11 12
Speedometer
1
2
3
4 5 6 7 8 9 10 11 12
[108B]
1
2
3
4 5 6 7 8 9 10 11 12
To
[108A]
Tachometer
Ignition
Keyswitch
Relay
15A
Instruments
[1B] [1A]
Fuse
1
2
Main to Interconnect
3
[2A]
1
2
3
4 5 6 7 8 9 10 11 12
Harness
4
Data Link
[2B]
1
2
3
4 5 6 7 8 9 10 11 12
[91A]
Main to Interconnect
15A
Harness
Ignition
Fuse
15A
12
Battery
[10B]
Fuse
[10A]
ICM
Figure 2-7. Diagnostic Check: FLHX, FLHT/C (Carbureted)
Table 2-3. Wire Harness Connectors in Figure 2-7.
NO.
DESCRIPTION
TYPE
LOCATION
[1]
Main to Interconnect Harness
12-Place Deutsch (Black)
Inner Fairing - Right Radio Support Bracket
[2]
Main to Interconnect Harness
12-Place Deutsch (Gray)
Inner Fairing - Right Fairing Support Brace
[10]
ICM
12-Place Deutsch
Under Right Side Cover
[27]
Radio
23-Place Amp
Inner Fairing - Back of Radio (Right Side)
Cavity in Crossmember at Rear of Battery Box
[30]
TSM/TSSM
12-Place Deutsch
(Under Seat)
[39]
Speedometer
12-Place Packard
Inner Fairing (Back of Speedometer)
[91]
Data Link
4-Place Deutsch
Under Right Side Cover
[108]
Tachometer
12-Place Packard
Inner Fairing (Back of Tachometer)
[156]
Main to Interconnect Harness
6-Place Deutsch
Inner Fairing - Right Fairing Support Brace
2006 Touring: Instruments
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f2353m8x
BK
GY
LtGN/V
LtGN/V
BK
BN/GY
O
1
2
3
4
5 6 7 8 9 10 11 12
[30B]
1
2
3
4
5 6 7 8 9 10 11 12
[30A]
BN/GY
TSM/TSSM
BK
1
2
3
4 5 6 7 8 9 10 11 12
[39B]
1
2
3
4 5 6 7 8 9 10 11 12
[39A]
GY
Speedometer
15A
Instruments
Fuse
15A
Battery
Fuse
1
To
2
Ignition
Keyswitch
3
Relay
4
Data Link
[91A]
15A
Ignition
Fuse
12
[10B]
[10A]
ICM
12
Figure 2-8. Diagnostic Check: FLHR/S (Carbureted)
Table 2-4. Wire Harness Connectors in Figure 2-8.
NO.
DESCRIPTION
TYPE
LOCATION
[10]
ICM
12-Place Deutsch
Under Right Side Cover
Cavity in Crossmember at Rear of
[30]
TSM/TSSM
12-Place Deutsch
Battery Box (Under Seat)
[39]
Speedometer
12-Place Packard
Under Console (Back of Speedometer)
[91]
Data Link
4-Place Deutsch
Under Right Side Cover
2-8
2006 Touring: Instruments
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f2353n8x
[156B] [156A]
Radio
[27A]
Main to Interconnect
6
6
[27B]
5
5
Harness
9
4
4
BK
3
3
GY
2
2
BK
LtGN/V
1
1
LtGN/V
O
1
2
3
4 5 6 7 8 9 10 11 12
[30B]
BN/GY
1
2
3
4 5 6 7 8 9 10 11 12
[30A]
BN/GY
TSM/TSSM
BK
[39B]
1
2
3
4 5 6 7 8 9 10 11 12
GY
1
2
3
4 5 6 7 8 9 10 11 12
[39A]
Speedometer
1
2
3
4 5 6 7 8 9 10 11 12
[108B]
1
2
3
4 5 6 7 8 9 10 11 12
[108A]
Tachometer
To
Ignition
15A
Keyswitch
Instruments
[1B] [1A]
Relay
Fuse
1
2
Main to Interconnect
3
Harness
1
2
3
4 5 6 7 8 9 10 11 12
4
Data Link
[2B]
1
2
3
4 5 6 7 8 9 10 11 12
15A
[2A]
Ignition
Main to Interconnect
Fuse
[91A]
Harness
[78B]
15A
5
ECM
Battery
[78A]
Fuse
Figure 2-9. Diagnostic Check: FLHX, FLHT/C/U, FLTR (Fuel Injected)
Table 2-5. Wire Harness Connectors in Figure 2-9.
NO.
DESCRIPTION
MODEL
TYPE
LOCATION
Main to Interconnect
FLHT/C
12-Place Deutsch (Black)
Inner Fairing - Right Radio Support Bracket
[1]
Harness
FLTR
12-Place Deutsch (Black)
Inner Fairing - Below Radio (Right Side)
FLHT/C
12-Place Deutsch (Gray)
Inner Fairing - Right Fairing Support Brace
Main to Interconnect
[2]
Harness
FLTR
12-Place Deutsch (Gray)
Inner Fairing - Below Radio (Right Side)
[27]
Radio
All
23-Place Amp
Inner Fairing - Back of Radio (Right Side)
Cavity in Crossmember at Rear of
[30]
TSM/TSSM
All
12-Place Deutsch
Battery Box (Under Seat)
FLHT/C
12-Place Packard
Inner Fairing (Back of Speedometer)
[39]
Speedometer
FLTR
12-Place Packard
Under Bezel (Back of Speedometer)
[78]
ECM
All
36-Place Packard
Under Right Side Cover
[91]
Data Link
All
4-Place Deutsch
Under Right Side Cover
FLHT/C
12-Place Packard
Inner Fairing (Back of Tachometer)
[108]
Tachometer
FLTR
12-Place Packard
Under Bezel (Back of Tachometer)
Main to Interconnect
FLHT/C
6-Place Deutsch
Inner Fairing - Right Fairing Support Brace
[156]
Harness
FLTR
6-Place Deutsch
Inner Fairing - Below Radio (Right Side)
2006 Touring: Instruments
2-9
HOME
f2353o8x
BK
GY
LtGN/V
LtGN/V
BK
BN/GY
O
1
2
3
4 5 6 7 8 9 10 11 12
[30B]
1
2
3
4 5 6 7 8 9 10 11 12
[30A]
BN/GY
TSM/TSSM
BK
1
2
3
4 5 6 7 8 9 10
11
12
[39B]
1
2
3
4 5 6 7 8 9 10
11
12
[39A]
GY
Speedometer
15A
Instruments
To
Fuse
15A
Ignition
Battery
Keyswitch
Fuse
Relay
1
15A
2
Ignition
3
Fuse
4
Data Link
[91A]
[78B]
5
ECM
[78A]
Figure 2-10. Diagnostic Check: FLHR/C/S (Fuel Injected)
Table 2-6. Wire Harness Connectors in Figure 2-10.
NO.
DESCRIPTION
TYPE
LOCATION
Cavity in Crossmember at Rear of
[30]
TSM/TSSM
12-Place Deutsch
Battery Box (Under Seat)
[39]
Speedometer
12-Place Mini-Deutsch
Under Console (Back of Speedometer)
[78]
ECM
36-Place Packard
Under Right Side Cover
[91]
Data Link
4-Place Deutsch
Under Right Side Cover
2-10
2006 Touring: Instruments
HOME
Diagnostic Check (Part 1 of 2)
Does engine
start?
YES.
YES.
NO.
NO.
Starts and
Starts, then
Cranks, but
Engine will not
runs.
stalls.
will not start.
crank.
Check for DTC’s. See
For carbureted models, see
For carbureted models, see
See Section 1.2 STARTING
Section 2.3 SPEED-
Section 4.10 STARTS,
Section 4.9 ENGINE
SYSTEM DIAGNOSIS.
OMETER SELF DIAG-
THEN STALLS. For EFI
CRANKS, BUT WILL NOT
NOSTICS
models, see Section 5.12
START. For EFI models, see
Codes found?
STARTS, THEN STALLS.
Section 5.10 ENGINE
CRANKS, BUT WILL NOT
START.
YES
NO
Refer to applicable DTC priority chart.
Unable to enter diagnostic mode.
All diagnostic codes are listed on page
With ignition switch OFF, press and
2-6 in Table 2-2. Codes are listed by
release odometer reset switch.
priority.
Does odometer display appear with
display backlighting?
YES
NO
STOP
Check for continuity to ground on terminal 7
1
of speedometer. Wiggle harness during con-
tinuity check. Continuity present?
Go to Diagnostic
Check (Part 2 of 2).
YES
NO
Check for battery voltage at
terminal 5 of speedometer
Locate and repair open
while wiggling harness. Bat-
between terminal 7
tery voltage continuously
and ground.
present?
YES
NO
With connector [39] disconnected from
Locate and repair open
speedometer, check continuity (with ignition
between terminal 5 and
switch OFF) between terminals 8 and 11 on
battery fuse.
Breakout Box. Continuity present when
speedometer reset switch is depressed and
infinity when released?
YES
NO
Replace speedometer.
Replace speedometer
reset switch.
2006 Touring: Instruments
2-11
HOME
Diagnostic Check (Part 2 of 2)
Continued from Diagnostic Check (Part 1 of 2).
Perform “wow” test. See Section 2.3 SPEEDOMETER SELF DIAGNOSTICS.
The following features should be functional
1) backlight should illuminate
2) needle should sweep its full range of motion
3) LED’s that should illuminate:
• check engine
• battery
• security (all models)
4) LED’s that may illuminate:
• low fuel (EFI models)
• cruise (although not cruise equipped on some models)
Are all features functional?
YES
NO
Turn key to ACC. Is
With ignition switch turned to
backlight present?
IGN, check for battery voltage
1
at terminal 1 of Breakout Box.
Battery voltage present?
YES
NO
YES
NO
Is problem intermittent?
Check for battery voltage at
Replace Speedometer.
Is instrument
breakout box terminal 6.
fuse blown?
Battery voltage present?
YES
NO
YES
NO
Replace speedometer.
Is accessory fuse
Locate and repair
Locate and repair open
blown?
source of fault.
between terminal 1 of
Replace fuse.
connector [39] and
instrument fuse.
YES
NO
Locate and repair
Locate and repair open on O/W
source of fault.
wire between termin al 6 of con-
Replace fuse.
nector [39] and accessory fuse.
YES
YES
NO
Intermittent vehicle speed
indication.
Repeat Diagnostic Check
Tachometer Inoperative
while wiggling harnesses.
(no engine speed).
Intermittent present?
Remove and inspect VSS.
Debris present?
See Test 2.4 (Part 1 of 2).
YES
NO
YES
NO
Locate and repair
No trouble found.
intermittent.
Remove debris.
Check for damaged wiring/
Reinstall VSS.
loose connection between
VSS and ICM/ECM. Is wiring
damage/loose
connection present?
YES
NO
Locate and repair
Replace Speedometer.
source of fault.
2-12
2006 Touring: Instruments
HOME
SPEEDOMETER SELF DIAGNOSTICS
2.3
GENERAL
The speedometer is capable of displaying and clearing
speedometer, tachometer, TSM/TSSM, and ICM/ECM DTC’s.
60
40
50
70
30
50
40
80
30
90
20
MPH
RPM x100
DIAGNOSTICS
20
100
10
10
110
0
120
0
Diagnostic Tips
TI
-D
-D
● For a quick check of speedometer function, a “wow” test
can be performed. Press and hold odometer reset switch
1
then turn ignition switch ON. Release reset switch. Back-
2
3
5
ground lighting should illuminate, speedometer needle
4
should sweep its full range of motion, and indicator
f2160x8x
lamps [battery, security, low fuel
(EFI models) check
1.
Check Engine
engine and cruise should illuminate. Some lamps may
2.
Low Fuel
illuminate even though they do not apply to the vehicle.
3.
Battery
For example, the cruise lamp may illuminate although
4.
Security
this feature does not apply to some models.
5.
Cruise (Where Applicable)
● If instrument module fails “wow” test, check for battery,
Figure 2-11. Icons
ground, ignition, speedometer reset switch and acces-
sory to speedometer. If any feature in the speedometer is
non-functional, see Section 2.2 INITIAL DIAGNOSTIC
CHECK: SPEEDOMETER.
Diagnostic Notes
Use of speedometer self diagnostics assumes that DIGITAL
TECHNICIAN (Part No. HD-44750) is not available.
The reference numbers below correlate with the circled num-
bers in the Speedometer Self Diagnostics (chart)
1.
To exit diagnostic mode, turn ignition switch OFF.
2.
To clear DTC’s for selected module, press speedometer
f2080x8x
reset switch for more than 5 seconds when code is dis-
played.
Figure 2-12. Ignition Switch (FLHX, FLHT/C/U, FLTR)
2006 Touring: Instruments
2-13
HOME
Speedometer Self Diagnostics (chart)
While holding odometer reset switch in,
turn ignition switch to IGN. Make sure
Run/Stop switch is in RUN position.
1
Release reset switch.
Does “diag” appear?
YES
NO
Press and release reset
See Section 2.2 INITIAL
switch.
DIAGNOSTIC CHECK:
“PSSPT” appears.
SPEEDOMETER.
To display DTC’s for the
ECM/ICM, press and
”P” flashing.
hold reset switch for
more than 5 seconds.
To choose TSM/
TSSM, press and
release reset switch.
To display DTC’s for
”S” flashing.
TSM/TSSM, press and
hold reset switch for
more than 5 seconds.
To choose Speedometer,
Device
response?
press and release reset
switch.
NO
YES
“no rsp” displayed.
To display DTC’s for
See applicable code from
”SP” flashing.
speedometer, press and
other modules. Models not
hold reset switch for more
equipped with a tachometer
than 5 seconds.
will display “no rsp” normally.
If “no rsp” displayed on odom-
eter on tachometer equipped
To choose Tachometer,
vehicle, see Section 2.4
“none” displayed.
press and release reset
SPEEDOMETER/TACHOMETER.
switch.
DTC
2
displayed.
To display DTC’s for
tachometer, press and
Press and release
Press and release
”T” flashing.
hold reset switch for more
reset switch. Part num-
reset switch.
than 5 seconds.
ber of module will be
Are more DTC’s
displayed.
displayed?
NO
To choose ICM, press and
YES
release reset switch.
“end” displayed.
To clear all DTC’s for
selected module hold reset
switch for more than 5 sec-
onds. If DTC’s are not to be
cleared, Press and release
reset switch. Part number of
module will be displayed.
Press and release reset
switch again to continue to
next module.
Figure 2-13. Speedometer Self Diagnostics
2-14
2006 Touring: Instruments